Packaging device, particularly for fragile goods

ABSTRACT

The invention is concerned with a packaging insert device adapted to prevent contact between a product and its container so as to support the product in a position in which shocks to the packaged product caused by, for example, dropping the package, are absorbed by the resilient properties of stiffly resilient lightweight plastics spacer devices received in apertures formed in end panel pieces, collars and the like formed of cardboard or other suitable insert material. A spacer device may comprise at least one protuberance projecting from a plate member and passing through a respective aperture of the plate member. Preferably multiple spacer devices comprise two or more plate members joined at a hinge line so that the plate members can be arranged, for example, into an L-shape to bridge corners and abutting edges of said end pieces or collars.

BACKGROUND OF THE INVENTION

The invention is concerned with improvements in or relating to packagingdevices, particularly but not exclusively for use in the packaging ofmore or less fragile goods in a carton or similar box.

When products are packaged for storage and transit, it is necessary notonly to restrain the products from undue movement within the carton, butalso to protect them from damage by shock and vibration. The use ofenergy absorbing, resilient materials is therefore well established inindustry and is conventionally known as cushion packaging.

Cushion packaging is intended to minimise the damaging effect on thepackaged product being dropped, or from vibration due, for example, tothe engines of the vehicle or ship in which the cartons are transported.Drop heights likely to be encountered actually increase when the weightof the carton is reasonably light compared with cartons that requireeven moderately robust lifting equipment. It has been found that theshock is better absorbed if the product is allowed to move through avery small distance in the carton and therefore the strength of theenergy absorbing materials must be balanced against the required degreeof resilience.

The use of preformed inserts of expanded plastics bead material has beenfound to give good results in a wide variety of applications, but it iscommonly found that larger sized inserts are used for the sake ofapparent security for the product than are actually necessary under mostconditions. Such over-use of plastics materials is to be avoided wherepossible on environmental grounds as well as those of cost and handling.

SUMMARY OF THE INVENTION

The present invention sets out, therefore, to minimise the volume ofresilient packaging inserts of plastics material for use in cartons,cases, boxes or the like.

The invention provides a packaging insert device for use as an insertwithin a carton or the like wherein the insert is adapted to support aproduct within said carton out of contact with interior surfaces ofwalls of said carton, said device comprising a panel member having atleast one aperture formed therein, and a spacer device of stifflyresilient material and provided with at least one protuberance, the oreach protuberance being adapted to be received in said aperture(s) so asto project beyond the panel member.

Advantageously, there may be provided at least two of said aperturesformed in the panel member, a second aperture being formed in closepositional relationship to the first aperture, said spacer device havinga plurality of protuberances adapted to be received in respective onesof said apertures.

Preferably, said panel member further may comprise a flange formed atleast partially along one edge thereof and extending at leastsubstantially at right angles to the panel member, said panel memberhaving said first aperture formed in a marginal portion thereof adjacentsaid flange and said second aperture formed in the flange in closerelationship to the first aperture.

Alternatively, said panel member may comprise two flanges, said firstaperture being formed in one of said flanges and said second aperturebeing formed in said second flange in close relationship to the firstaperture.

Conveniently, said spacer device may comprise two plate members eachjoined to a neighbouring plate at adjacent edges. Said plates may bemutually perpendicular, or substantially perpendicular to each otherand, being joined at adjacent edges thereof, provide the spacer memberwith an L-shaped cross-section, outer surfaces of said plate membersbeing provided with said protuberances which are adapted to be receivedin said first and second apertures respectively so as to project beyondsaid flanged panel member.

Preferably, said protuberances may be provided with locking or wedgesurfaces arranged to prevent unintentional withdrawal from theapertures.

In some circumstances, it may be preferable to provide a single platemember having at least two protuberances, for use in bridging endportions of an elongate panel member folded end-to-end in the manner ofa collar and having one of said apertures formed at each end portionthereon into which the protuberances of the plate member are received.

The invention further provides a spacer member for use in a packaginginsert device as described above and comprising an initially flat platehaving a centre line formed therein, a first protuberance being providedon a surface of said plate at one side of said centre line and a secondprotuberance being provided on the other side of said centre line.Advantageously, the construction and arrangement may be such that theplate is capable of being folded about the centre line to form said twoplate members.

Advantageously, said plate member(s) may be provided on the oppositesurface to that from which the protuberances extend, with a flat,slightly raised portion, intended in use to contact a packaged product,said protuberances contacting a carton containing said product.Preferably, said raised portion may have chamfered edges.

Advantageously, said panel member may be of card, cardboard or similarmaterial. Preferably said spacer members may be moulded of expandedbeads of polypropylene or other suitable plastics materials in a desiredrange of size and density.

There will now be described an example of a packaging device and ofspacer members according to the invention. It will be understood thatthe description is given by way of example only and not by way oflimitation.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is an exploded perspective view of a product received in apackaging device including a first example of spacer devices accordingto the invention;

FIG. 2 is a plan view of the packaging device of FIG. 1 in an initial,flat, condition;

FIG. 3 is a perspective view of one of the spacer devices of FIG. 1;

FIG. 4 shows a perspective view of a multiple spacer device according tothe invention;

FIG. 5 shows one of a second example of spacer devices;

FIG. 6 shows a multiple spacer device of FIG. 4 in a folded condition;

FIG. 7 shows a sheet of spacer devices as shown in FIG. 4 in anas-moulded condition;

FIG. 8 shows a part sectional view of a portion of a product with apackaging device according to the invention received in a carton;

FIG. 9 shows an exploded perspective view of a product received inanother packaging device including alternative arrangements of spacerdevices;

FIG. 10 illustrates an end spacer device and two alternativeintermediate spacer devices or collars including further alternativearrangements of spacer devices;

FIG. 11 shows a corner spacer device in an initial, flat, condition;

FIG. 12 shows the device of FIG. 11 in a folded condition;

FIGS. 13 to 15 shows stages in the assembly of spacer devices in thedevice of FIG. 12;

FIG. 16 shows a rear surface of a spacer device according to theinvention; and

FIG. 17 illustrates a two-stage moulding technique for producing spacerdevices.

DESCRIPTION OF ILLUSTRATED EMBODIMENT

A packaging device 2 to be described below is intended for use inassociation with an outer container 4 or box, conveniently of corrugatedboard or cardboard as shown in FIG. 6. The interior dimensions of theouter container 4 are such that the packaging device is received in afirm fit therewithin. Two such packaging devices 2 are used to encloserespective end portions of a relatively fragile product 6, which may befor example electronic equipment, say, a speaker unit. Each of the twodevices 2 comprises a panel 8 having four flanges 10, 12, formed alongedges thereof. The device may be formed from a cardboard blank 14 as inthe present example and shown in FIG. 2.

A plurality of apertures 16 are formed in the blank, in this example,six in the panel member, two in each of the flanges 10 and one in eachof the flanges 12. The flanges are foldable through an angle of 90° soas to form a tray-like configuration, by means of crease- or fold-lines18 which provide hinge zones.

When the blank 14 has been folded along the lines 18, corners so formedbetween adjacent flanges 10, 12 may be fastened by any suitable means.

FIG. 3 shows a single spacer device 20, one of which may be insertedinto each of the apertures 16 shown in FIG. 2. The spacer devicecomprises a plate member 22 formed so as to be thickened at 21 foradditional cushioning. However, a preferred arrangement is to provide amultiple device as described below.

A multiple spacer device 20 will now be described. Two devices 20comprising a pair of plate members 22 are joined at a hinge line 24,outwardly facing surfaces of the plate members 22 each having aprojection 26 extending therefrom. The projections 26 have taperingcross sections, the base of the projections having dimensionscorresponding to those of the apertures 16 in order to be a firm snap-infit therein, as will be explained. The spacer devices of the presentexample are conveniently moulded from polypropylene beads and arestiffly resilient when compressive force is applied. However, to enhancethe firm fit of the projections 26 in the apertures 16, wedge portions28, 38, may be provided as shown in FIGS. 5 and 6 on outwardly facingsurfaces of each pair of projections 26'. It will be understood that thedevices may be dimensioned to fit precisely into a container, takingaccount also of the weight and fragility of the product and selectingthe density (resilience) of the material from which the spacer devicesare moulded. It will be noticed that the reinforcement portion 21 ofFIG. 6 is provided with grooves 36, the purpose of which will beexplained below.

FIG. 7 shows a sheet of spacer devices as shown in FIGS. 5 and 6, in anas-moulded condition, from which sheet spacer members may be detached inwhichever configuration they may be required according to the conditionsof use.

FIG. 8 shows the panel 8 of FIG. 1 in position in the container 4. Itwill be observed that the hinged double device 20 is suitable for use asa corner member.

FIG. 9 shows a panel 40 having flanges 42, in apertures of which arereceived projections 44 of eight L-shaped devices 46. As an alternative,a panel 48 is shown having flanges 50, in apertures of which arereceived projections 52 of four L-shaped devices 54. Each device 54comprises two hinged plate members 56 and three of the projections 52.On interior surfaces of the plate members 56 are provided flat, slightlyraised portions 58 adapted to contact a product 60, and to space it fromthe cardboard of the panel 48 or its flanges 50. The portions 58 whichare equivalent to the reinforcing portions 21 described above havebevelled edges 62. A collar-like arrangement is also shown in which afolded panel 63 provides apertures for a plurality of single devices 20(FIG. 3).

FIG. 10 shows a device incorporating a number of alternativearrangements. Panels 64 are provided with flanges 66, folded to formcorner regions in which abutting edges of the flanges 66 are bridged byL-shaped spacer devices 20 (as shown in FIGS. 3 or 5) with the additionof single spacer devices at 68. In the present example, the bridgingaction of the devices 20 assists in assembly of the packaging around theproduct 70.

A similar device (not shown) will be provided at the opposite end of theproduct 70.

However, where the length of the product between the devices accordingto the invention exceeds a given distance, it may be advantageous toprovide intermediate support and protection in the form of a collar-likearrangement indicated at 72. This comprises a panel 74 folded so thatits ends abut at 76 and are bridged by a linear device 78 comprising twoprojections 80 passing through respective apertures (not visible) in thefolded ends. Three additional devices 78 are received in the remainderof the panel 74.

An alternative collar-like arrangement is also shown in FIG. 10, inwhich edges of a folded panel 82 abut at a corner 84. In this lay-out, afirst L-shaped device 86 is inserted to bridge the abutting edges, threeother devices 86 being provided at the remaining corners. However,corner regions of such end devices and collars may be secured togetherby providing additional apertured flange portions that when assembledoverlap an adjacent flange portion so that apertures therein aresuperimposed, allowing a projection 26 to pass through both apertures ina push-fit or snap-fit, thus securing the flange portions together in anassembled condition and obviating the need for the use of securing tape.

In a further example, a corner device may be provided as shown in FIGS.11 to 15.

FIG. 11 shows a cardboard blank 88 which comprises four panel portionsA-D, formed by fold lines 90 and a slot 92. Four apertures 94 are formedin the blank which is assembled as shown in FIG. 12, with the aperturesof panel portions A and D in alignment.

FIG. 13 shows a triple spacing device 96 having projections X, Y and Z,fold lines 98 being provided to enable the device to assume theformation shown in FIG. 14. The parts are brought together as shown inFIG. 15 so that the projection X is received in panel portion B,projection Y in panel portion C and projection Z in panel portions A andD so as to secure the latter together and maintain the desiredcorner-like formation.

In all the above examples, the projections are a push-fit, force-fit orsnap-fit into the appropriate apertures according to their configurationand the characteristics of the plastics material from which they aremoulded. In FIG. 16, an underside view of a spacer device shows thepresence of a discontinuity in the form of a recess 100 in the thickenedportion 21. Alternatively, the presence of ridges and furrows, such asthe grooves 36 (FIG. 6), may provide a suitable discontinuity whichpermits the device more readily to flex as the projection 26 is insertedinto the aperture to assist in assembly. Alternatively, a raised orrelief discontinuity may be provided.

In producing any of the spacing devices described above, a two-stagemoulding technique may be used. The bead material is compressed in stageI into a mould member 102 (see FIG. 17) having a moulding surface 104provided with cavities 106 corresponding to the projections. When thematerial is partially set, a second moulding plate 108 is brought intooperation in stage II to further compress the bead material forming theplate member 22. The second moulding plate 108 is provided with a ridge110 which forms the required hinge line 24. FIG. 7 shows a multiplemoulding of a plurality of spacer devices 20, break-lines 34 permittingdivision of the multiple moulded product into single units. FIG. 17 alsoshows the extension of the mould members into the multiple mode withprojections 112 provided on the moulding plate 108 to produce thebreak-lines 38 between the individual products.

In use of an example according to the invention, two blanks 14 will berequired for a product such as electronic equipment 6 shown in FIGS. 1and 8. The flanges 10, 12 on each blank are folded about lines 18 andthe spacer devices are also folded about line 24 as shown in FIG. 5 andfitted to the tray-like device 2 so that the projections 26 (26') extendoutwardly from the apertures 16, each spacer device fitting within the90° angle formed between the flanges 10 or 12 and the panel 8 andinserted without the use of tape or adhesives. The ends of the unit 6are then inserted into the assembled tray-like device 2 and the whole isplaced within the cartons 4 so that the only contact between the unit 6and the carton is through the projections 26 (26') which span the spacebetween the tray-like devices 2 and the carton 4. It will be understoodthat the dimensions are chosen so that the unit 6 fits closely withinthe tray-like devices 2 and outwardly facing surfaces 42 of theprojections 26 (26') are in close contact with the carton 4.

If desired, further packaging means may be used in addition to thedevices 2 shown above. Conveniently, these may comprise shaped cardboardinserts. Various modifications may be made within the scope of theinvention as defined in the following claims.

I claim:
 1. A packaging insert device for use as an insert within acarton wherein the insert is adapted to support a product within saidcarton out of contact, with interior surfaces of walls of said carton,said device comprising a panel member having at least two aperturesformed therein, and a spacer device of stiffly resilient material andprovided with at least two protuberances, each protuberance beingadapted to be received in a respective one of said apertures so as toproject beyond the panel member, and wherein said spacer devicecomprises an initially flat plate member having a center line formedtherein, at least a first of the protuberances being provided on asurface of the plate member at one side of the center line and at leasta second of the protuberances being provided on the other side of saidcenter line.
 2. An insert device as claimed in claim 1, wherein saidpanel member comprises a first panel portion and a second panel portionformed at least partially along one edge of said first panel portion andextending at least substantially at right angles thereto, each saidpanel member portion having one of said apertures formed adjacent tosaid edge thereof.
 3. An insert device as claimed in claim 2, whereinsaid panel member comprises a further panel portion formed at leastpartially along a second edge of the first panel portion and extendingat least substantially at right angles to each of said first and secondpanel portions, said further panel portion being provided with a furtherone of said apertures.
 4. An insert device as claimed in claim 3,wherein said panel portions are folded so as to produce a partiallyoverlapping configuration, so that a protuberance is received in alignedcongruent apertures of respective panel portions to maintain saidconfiguration.
 5. An insert device as claimed in claim 3, wherein saidfirst panel portion comprises a main panel portion and said second andfurther panel portions are in the form of flanges formed at respectiveedges of said main panel portion.
 6. An insert device as claimed inclaim 3, wherein said first and further panel portions are four innumber and are arranged end-to-end in a continuous band or collar.
 7. Aninsert device according to claim 1, wherein said plate member has saidprotuberances projecting from one surface thereof and a raised portionprovided on an opposite surface of the plate number to eachprotuberance, said raised areas being adapted to be in contact with saidproduct and said protuberances being adapted to be in contact with oneof said carton walls when the insert device is in use.
 8. An insertdevice according to claim 7, wherein the protuberances of said platemembers are formed with wedge portions to enhance their fit within theapertures of the panel members.
 9. An insert device according to claim1, wherein said center line comprises a hinge line or area.
 10. Aninsert device according to claim 1, wherein the flat plate member ismolded, together with said protuberance, from a stiffly resilient,lightweight plastics material.
 11. An insert device according to claim10, wherein the plastics material is selected from the group consistingof polyethylene, polyurethane and polypropylene.
 12. An insert deviceaccording to claim 10, wherein the plastics material comprises moldedfoam.